R1150GSA Auxiliary Cooling Fan Project

[zekeq]

After dealing with my overheating 2002 R1150 GSA during the eclipse traffic last spring, I’ve been noodling on how to add auxiliary radiator fans. In August I tested using two 60x60x25mm fans on an idling/still bike, and got good results.

Post in thread 'Air/oil cooled camhead oil cooler fan':
https://forums.bmwmoa.org/threads/air-oil-cooled-camhead-oil-cooler-fan.105496/post-1331338

Today I modeled a mount design and did a cardboard fit check prototype (it fit!).

The design is two metal parts of 3mm thick aluminum, two fans, and an adhesive backed fiberglass/aluminum foil air duct to prevent the fan bodies, which are plastic, from directly contacting the cooling fins. The flat plate slides under the radiator and will be sandwiched between the radiator and the large plastic housing which supports the headlights. The second metal part is an L bracket with three M3 tapped holes. It will be slid in from underneath/behind and r then the flat plate will slide under it and the M3’s secured. Then the radiator bolts will be retightened and the beak trim reassembled. The cooling hoses will remain attached during assembly. I also will not be drilling any holes or making any permanent modifications to the bike.

I bought an automatic thermostat, but for now I’m going to keep it simple and use a rocker switch tapping the headlight 12V line, which has plenty of capacity as I switched the headlights to LED earlier this year. I wanted the fans to be stealth, which is why I opted not to do an easier front mounted design. After I verify functionality I can consider speed controls and thermostatic engagement.

I’ll post the CAD models and bill of materials once I’ve successfully built and installed the system. For now here are a few shots of the project in progress.

Happy December!

To be continued…

 

[khfranck]

That's super cool (get it?). I'm following. I've had similar overheating issues with my 99R1100RT, but don't think this kit would fit under the tupperware.

 

[detbmw]

After dealing with my overheating 2002 R1150 GSA during the eclipse traffic last spring, I’ve been noodling on how to add auxiliary radiator fans. In August I tested using two 60x60x25mm fans on an idling/still bike, and got good results.

Post in thread 'Air/oil cooled camhead oil cooler fan':
https://forums.bmwmoa.org/threads/air-oil-cooled-camhead-oil-cooler-fan.105496/post-1331338

Today I modeled a mount design and did a cardboard fit check prototype (it fit!).

The design is two metal parts of 3mm thick aluminum, two fans, and an adhesive backed fiberglass/aluminum foil air duct to prevent the fan bodies, which are plastic, from directly contacting the cooling fins. The flat plate slides under the radiator and will be sandwiched between the radiator and the large plastic housing which supports the headlights. The second metal part is an L bracket with three M3 tapped holes. It will be slid in from underneath/behind and r then the flat plate will slide under it and the M3’s secured. Then the radiator bolts will be retightened and the beak trim reassembled. The cooling hoses will remain attached during assembly. I also will not be drilling any holes or making any permanent modifications to the bike.

I bought an automatic thermostat, but for now I’m going to keep it simple and use a rocker switch tapping the headlight 12V line, which has plenty of capacity as I switched the headlights to LED earlier this year. I wanted the fans to be stealth, which is why I opted not to do an easier front mounted design. After I verify functionality I can consider speed controls and thermostatic engagement.

I’ll post the CAD models and bill of materials once I’ve successfully built and installed the system. For now here are a few shots of the project in progress.

Happy December!

To be continued…

I want to do this to my 2001 R1150GS. It goes to six bars if the sun shines on it in July & August.

 

[zekeq]

I want to do this to my 2001 R1150GS. It goes to six bars if the sun shines on it in July & August.

Once I’ve got it all together (version 2 arrives next week) I’ll be posting the CAD models and bill of materials along with some instructions. Stay tuned!

 

[zekeq]

That's super cool (get it?). I'm following. I've had similar overheating issues with my 99R1100RT, but don't think this kit would fit under the tupperware.

We will see! (I know this gent!)

 

[zekeq]

It's alive!!!!!

Well, no, but the auxiliary fan an switch system are installed and working as designed.

Link to the full technical package - CAD files (SW 2023 & STEP), BOM, README instructions, data sheets for all the stock items, as well as the price I paid in USD, excluding shipping. Use at your own risk:

Google Drive Link

Progress since my last post:

• Revised design to be acceptable to rapid prototype service 'SendCutSend'
• Revised materials and finished for a shorter package, the original design was about 6mm too tall
• Revised & simplified hardware.

Previous to this installation I had replaced the head lamp bulbs with LED units, so even with the fans in place I'm still using less power than the original bike, so I'm not worried about alternator output.

I found the SendCutSend service to be fairly priced. I'm a machine tool designer by trade, and it's amazing to me that you can get custom stuff for relatively short money. Goods took about 2 weeks to deliver and I had no issues with the service they provided, I would recommend them. I'm in no way affiliated with them, just a happy customer.

Here's a photo showing what it looks like from the front once everything was reassembled:


The unit before assembly:


The unit assembled from the sides & below before the beak was reassembled:



Revised cockpit - the fan switch is to the right and just below the tire pressure monitor on the left handlebar:



I have intentionally left out some adjacent projects from my documentation (the READ ME.rtf file in the link above) - when I added this fan, I also added a Thunderbox accessory relay, a Garmin ZumoXT2 and remote, as well as a 12V to USB C converter to supply my phone mount at right. All of these were attached to a 12AWG wire connected to a 30A fuse on a Bluesea battery post terminal fuse block, and run back to a terminal mounted Bluesea negative bus bar. And, just for fun a brand new OEM windshield.

All the new wiring is tucked up behind the instrument cluster. Time will tell if this was a wise choice, but none of these connections are mission critical and if they fail the bike still runs.

The fans themselves are IP69 so they're ready for the rain. The fiberglass batting may absorb some water, but I expect the heat from the radiator will dry it in short order. Time will tell.

Anyway, thanks for reading this, and I look forward to my next farkle (GD IT AUTOCORRECT I MEAN FARKLE not "CAROL")!

 

[omega man]

OM

 

[fbt80]

SendCutSend, very interesting. Vector/EPS is stock & trade in my advertising world.
Super clean execution Zekeq!

 

[zekeq]

SendCutSend, very interesting. Vector/EPS is stock & trade in my advertising world.
Super clean execution Zekeq!

Thanks!

There seemed to be a wide selection of fast turn fabrication providers out there, threw a dart and picked SendCutSend. Thanks for the alternative, I’ll take a look.

 

[fbt80]

Thanks!

There seemed to be a wide selection of fast turn fabrication providers out there, threw a dart and picked SendCutSend. Thanks for the alternative, I’ll take a look.

Oh, sorry wasn't clear. SendCutSend will also take an EPS as a file format that they take along with various CAD files I'd imagine. A EPS file is basically a vector based file allowing unlimited scaling without quality loss. I was just saying that those who work within the advertising/marketing field are very familiar with that file format, so I could use that to supply to SendCutSend for project templates.

 

[bc1100s]

It will be interesting to see the comparison results of this DIY modification. I'm thinking it could be significant.

 

[zekeq]

It will be interesting to see the comparison results of this DIY modification. I'm thinking it could be significant.

The temperature data and information is included in the linked thread in my first post, key image from that is this. Dark blue is engine minus ambient temperature.

 

[zekeq]

Ah, gotcha. Encapsulated Post Script, been a minute since I used that format. The .STP files are basically a 3D version of those, but with fixed dimensions & static shapes. They can be imported into many CAD systems, but do not contain an editable feature history. They’re vendor neutral like EPS.

 

[fbt80]

Damn zekeq, you're making me want to fabricate something. I think you have a product here.

 

[fbt80]

May build a carbon fiber battery box to house my Lithium battery. Right now, I have it in the OEM metal box with a wood block next to it to take up the space...I painted it black...it still bothers me.

 

[tangoalpha]

It's alive!!!!!

Well, no, but the auxiliary fan an switch system are installed and working as designed.

Link to the full technical package - CAD files (SW 2023 & STEP), BOM, README instructions, data sheets for all the stock items, as well as the price I paid in USD, excluding shipping. Use at your own risk:

Google Drive Link

Progress since my last post:

• Revised design to be acceptable to rapid prototype service 'SendCutSend'
• Revised materials and finished for a shorter package, the original design was about 6mm too tall
• Revised & simplified hardware.

Previous to this installation I had replaced the head lamp bulbs with LED units, so even with the fans in place I'm still using less power than the original bike, so I'm not worried about alternator output.

I found the SendCutSend service to be fairly priced. I'm a machine tool designer by trade, and it's amazing to me that you can get custom stuff for relatively short money. Goods took about 2 weeks to deliver and I had no issues with the service they provided, I would recommend them. I'm in no way affiliated with them, just a happy customer.

Here's a photo showing what it looks like from the front once everything was reassembled:
View attachment 100532

The unit before assembly:
View attachment 100533

The unit assembled from the sides & below before the beak was reassembled:
View attachment 100534
View attachment 100535View attachment 100536View attachment 100537

Revised cockpit - the fan switch is to the right and just below the tire pressure monitor on the left handlebar:
View attachment 100538


I have intentionally left out some adjacent projects from my documentation (the READ ME.rtf file in the link above) - when I added this fan, I also added a Thunderbox accessory relay, a Garmin ZumoXT2 and remote, as well as a 12V to USB C converter to supply my phone mount at right. All of these were attached to a 12AWG wire connected to a 30A fuse on a Bluesea battery post terminal fuse block, and run back to a terminal mounted Bluesea negative bus bar. And, just for fun a brand new OEM windshield.

All the new wiring is tucked up behind the instrument cluster. Time will tell if this was a wise choice, but none of these connections are mission critical and if they fail the bike still runs.

The fans themselves are IP69 so they're ready for the rain. The fiberglass batting may absorb some water, but I expect the heat from the radiator will dry it in short order. Time will tell.

Anyway, thanks for reading this, and I look forward to my next farkle (GD IT AUTOCORRECT I MEAN FARKLE not "CAROL")!

Bravo! Absolutely genius and brilliantly executed Sir! I’m looking forward to hearing your long term review on this project.